NTGF DEVELOPMENT PROJECT Doc.

No: OHCS-PROC-23
Revision: A
Date: 25-06-2010
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CONTENTS
1.0 SCOPE 3

2.0 APPLICATION 3

3.0 OBJECTIVE 3

4.0 RESPONSIBILITIES 3

5.0 DEFINITIONS 4

6.0 PROCEDURES 5

6.1 CALIBRATION OF PRESSURE GAUGE 5

6.2 PRESSURE TRANSMITTER - PNEUMATIC/ELECTRONIC 7

6.3 PRESSURE SWITCH - PNEUMATIC/ELECTRONIC 9

6.4 DIFFERENTIAL PRESSURE GAUGE 10

6.5 DIFFERENTIAL PRESSURE TRANSMITTER - PNEUMATIC/ELECTRONIC 11

6.6 DIFFERENTIAL PRESSURE SWITCH 13

6.7 TEMPERATURE INDICATORS 14

6.8 TEMPERATURE TRANSMITTER (FILLED SYSTEM TYPE) 15

6.9 TEMPERATURE TRANSMITTER (THERMOCOUPLE TYPE) 18

6.10 TEMPERATURE SWITCH 20

6.11 RESISTANCE TEMPERATURE DETECTOR 22

6.12 THERMOCOUPLE 23

6.13 TEMPERATURE TRANSMITTER (RTD TYPE) 24

6.14 LEVEL TRANSMITTER - INTERNAL DISPLACER TYPE P/E 26

6.15 LEVEL TRANSMITTER - EXTERNAL DISPLACER TYPE P/E 30

6.16 FLOAT OPERATED LEVEL SWITCH 33

6.17 SOLENOID VALVES 35

6.18 CONTROL VALVES 35

6.19 BALL VALVES 39

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6.20 CYLINDER VALVE 41

6.21 SAFETY RELIEF VALVE 43

6.22 RELAY, BOOSTER & CONVERTER 46

6.23 PNEUMATIC CONTROL CIRCUIT PRESS TEST 47

6.24 ELECTRONIC RECORDER 48

6.25 PNEUMATIC RECORDER 49

6.26 PRESSURE & TEMPERATURE RECORDERS 50

6.27 ORIFICE PLATE 54

6.28 FLOWMETER 54

6.29 FIRE & GAS SYSTEM 54

2.0 1.0 SCOPE:

This document identifies the various Work Method Statements and / or

individual Testing Procedures that are generally foreseen to be used during the
performance of the Instrument calibration works.

2.0 APPLICATION:

The work Method Statements/Procedures and the associated Check sheet(s),

shall be used, as may be deemed necessary during the performance of
Instrument Testing & Calibration activities related to the project.

3.0 OBJECTIVES:
These Work Method Statement/Procedure and Check sheets provide a reference
guideline based on good Engineering practice, for performance of the relevant
works.
However, it is explicitly understood that these procedures may be modified, if
deemed necessary, to suit the individual requirements of the Project in order to
comply with the requirements of the Contract Documents.
4.0 RESPONSIBILITIES:
4.1 Lead E & I Engineer assigned to the project shall be responsible for Supervising
and Coordinating the implementation of various Procedures and Check sheets,
with due considerations being given to the Project specification and Contract
requirements. He shall be also responsible for ascertaining the exact
requirements of Materials and Consumables on the Project.
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4.2 The instrument site Workshop Supervisor under the guidance of Lead E & I
Engineer shall be responsible for conforming to and complying with, the
applicable Calibration and Certification requirements of the Project
Specifications during execution of the Contract works.
4.3 The E&I Site Engineer shall also be responsible for ensuring that proper check
sheets which may be applicable for the Project are made available for recording
the results.
4.4 Inspector in conjunction with the Client Representative shall be responsible for
checking and witnessing the performance of the E&I works and completion of
the various Inspection/Test Record Check sheets to meet the documentation
requirements of the Project.
The E&I Inspector shall also be responsible for identifying any non-
conformance, observed during the execution of his responsibilities.

5.0 DEFINITIONS:

5.1 Inspection

Activities such as measuring, examining, testing, gauging one or more

characteristics of a product or service and comparing these with specified
requirements to determine conformity.
5.2 Testing

The determination or verification of the capability of an item to meet specified

requirements by sub testing the item to a set of physical, chemical,
environmental or operating conditions.
5.3 Calibration

The process of comparing the output of any given Instrument/Equipment against

the output of a Standard/ Reference Instrument, when the same input is applied
to both Instruments.
5.4 Pre-commissioning

Pre-commissioning activities are non-operating adjustments and Calibration and

cold alignment checks, generally carried out to ensure functionality of the item
to perform under specified conditions.

5.5 Ready for Commissioning

It is the state of condition of the Plant/Equipment or System, which has been

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erected in accordance with drawings, specifications instruction and applicable

Codes and Regulation and after all Pre-commissioning checks "under simulated
conditions" have been carried to the extent necessary for operating and
Commissioning the Plant/ Equipment or System.
5.6 Commissioning

Commissioning activities are associated with carrying out operational checks

and adjustments on individual equipment items and/or systems/subsystem to
facilitate plant start-up and operation of the facilities.
5.7 Quality

The totality of features and characteristics of a product or service that bear on

its ability to satisfy stated or implied needs.
5.8 Quality Assurance

All those planned and systematic actions necessary to provide adequate

confidence that a product or service will satisfy given requirements for quality.
5.9 Quality Control

The operational techniques and activities that are used to fulfil requirements for
quality.
5.10 Preservation

The process for maintaining the physical condition and characteristics of an

instrument/equipment item, from the time of receipt until its handing over upon
completion of the works, so that it can perform within the established design
parameters of its intended duty.
5.11 Non-Conformance
The non-fulfillment of specified requirements.
5.12 Concession, Waiver

Written authorization to use or release a quantity of material, components or

stores already produced but which do not conform to the specified requirements.
6.0 PROCEDURES:
6.1 CALIBRATION OF PRESSURE GAUGE:

a. For calibration either Manometric balance or Dead Weight Testers can be

utilized. Make connections as shown in Fig.1A & 1B in page no. 6.
b. Pressure gauges shall be ZERO set, if ZERO OFFSET is less than 10%
of full scale.
c. Pressure gauge shall be inspected for proper range and for evidence of
damage.
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d. Apply pressure gradually in steps of 0%, 25%, 50%, 75% and 100% of
the gauge range using pre-calibrated/certified equipment viz. Dead
Weight Tester, Manometer etc. Measure the reading on gauges for
accuracy and record it on the suitable test forms.
e. Reduce the pressure gradually in steps of 100%, 75%, 50%, 25%
and 0% and observe the reading and record the same.

f. In case of large numbers of pressure gauges to be calibrated, then pressure

comparator can be used with prior approval of Client.Standard pressure
gauges, thoroughly checked/calibrated using Dead Weight Tester can be
used as reference in this case. The standard gauge need to be re-
calibrated / tested against Dead Weight Tester after every 25 gauges
comparison.
g. Pressure gauges that do not function properly during initial operations
shall be replaced or repaired

PRESSURE
GUAGE

DEAD WEIGHT TESTER

FIG. - 1A
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PRESSURE GAUGE

MANOMETER
WATER/MERCURY

CALIBRATING
AIR SUPPLY

FIG. - 1B

TEST CIRCUIT FOR CALIBRATION OF PRESSURE GAUGE

6.2 PRESSURE TRANSMITTER – PNEUMATIC / ELECTRONIC:

a. Obtain the required actuating pressure by means of a variable Hydraulic

or pneumatic supply or by means of dead weight tester.
b. Calibrating Test Equipment shall be provided which can simulate
analogue input signals over the full transmitter range. Using standard
test equipment and making connections according to figure 2A and 2B
shown in page no. 8 proceed with Testing of the Transmitter.
c. The actuating pressure for the test shall be connected to the correct
instrument process connection via a tee piece. The leg of the tee
connected to the actuating pressure shall have a lock off valve and a vent
valve. The other leg of the tee shall be connected to a suitable test
gauge.
d. At zero input signal/the transmitter pressure, adjust zero adjustment
screw so that the out pressure gauge reads 3 psi or 0.2 Kg/Cm2.
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e. With lock off valve open and vent valve closed gradually increase the
pressure on the Transmitter input. Close lock off valve and check system
for leaks. [Shall be applied intermittently increasing from 0% - 100% and
reducing from 100% - 0% in steps of 25% as detailed on the calibration
sheet.
- Open vent valve and recheck zero.
f. The % error calculated from the results above shall not exceed the
manufacturers stated limits.
g. Transmitters with indicating scales shall where necessary have their
indicators also calibrated during test.
h. After testing, all spare entries and/or openings shall be appropriately
closed and/or blanked off to prove subsequent ingress of moisture or dirt.

STD PRESSURE GAUGE

PRESSURE GAUGE

STANDARD GAUGE

PRESSURE LOCK OF VALVE

TRANSIMITTER

DRAIN REGULATED
VALVE AIR SUPPLY

COMPARATOR
FIG. - 2A
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ELECTRONIC

STANDARD GAUGE DIGITAL MILLI AMMETER

mA
PRESSURE DC
TRANSIMITTER

COMPARATOR

FIG. -2B

6.3 PRESSURE SWITCH – PNEUMATIC / ELECTRONIC:

a. Calibration test equipment shall be provided which can simulate analogue input
signals over the specified switch range. During calibration, the generated input
signal value shall be visually displayed using standard test equipment.
b. Make connections as per figures shown below 3A & 3B in page no.9 & 10
respectively.
c. An electrical continuity meter shall be connected across the switch electrical
terminals to display switch continuity status.

d. The signal input shall be increased to a value where the switch contacts change
status. viz. the threshold position. This value of pressure at threshold position
shall be recorded.
e. The signal input shall then be reduced to the pre-test condition.

f. If necessary the set point and switch differential (if not of fixed type) shall be
adjusted to specifications as given in the engineering data sheet.
g. After calibration, pressure switches shall not be subjected to sudden
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movements, acceleration or shock and shall be protected from moisture, dirt and
large temperature variations.
h. After testing, all connections and entries shall be sealed to prevent the
subsequent ingress of moisture or dirt.

STANDARD GAUGE

PRESSURE
SWITCH

CONTINUITY TESTER

COMPARATOR

FIG. - 3A

PRESSURE
SWITCH

CONTINUITY TESTER

MANOMETER
WATER / MERCURY

CALIBRATING
AIR SUPPLY

FIG. - 3B

TEST CIRUIT FOR CALIBRATION OF PRESSURE SWITCH

6.4 DIFFERNTIAL PRESSURE GAUGE:

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a. For differential pressure gauge pressure shall be applied to "HP" Port only with "LP"
Port open to atmosphere and the equalizing valve closed.
b. Make connections according to figure 4 shown in page no.11.

c. Calibrating test equipment shall be provided which can simulate analogue input
signals over the full pressure gauge range. During calibration, the generated
input signal value shall be visually displayed using standard test equipment.
Pressure gauge input shall be applied incrementally from 0%---->100%---->0%
in the steps as detailed on the calibration sheet or 25% increments.

d. The pressure shall be applied by using a Dead Weight Tester. Water pump or by
the application of a regulated pneumatic, air supply. The selection of testing
equipment shall depend upon the pressure gauge type and range. Vacuum
measuring pressure gauge shall be connected to a vacuum pumping system and
Hg (Mercury) manometer indicator system.

e. The % error calculated from the results of the above test shall not exceed the
manufacturer’s limits.

STANDARD GAUGE
DIFFERENTIA L
PRESSURE
GA UGE LP PORT

HP PORT CONTINUITY TESTER

OPEN TO
ATMOSPHERE

COMPARATOR

FIG. - 4

TEST CIRCUIT FOR CALIBRATION OF

DIFFERENTIAL PRESSURE GAUGE

6.5 DIFFERENTIAL PRESSURE TRANSMITTER – PNEUMATIC / ELECTRONIC:

a. Make connections according to figures 5A & 5B shown in page no.12 & 13

respectively.
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b. The required actuating pressure shall be obtained by means of variable air

supply or dead weight tester.

c. Connect the output as follows:

(a) For electronic DPT : To a suitable test meter.

,,,,,
(b) For Pneumatic DPT : To a manometer or pneumatic calibrator.
,

d. Pressure shall be applied to the process impulse port using a Dead Weight
Tester water pump or by the application of a regulated pneumatic air supply.
The selection of testing equipment shall depend upon the transmitter type and
range. Vacuum measuring transmitters shall be connected to a vacuum
pumping system and mercury manometer indicator system.

e. Static ‘Pressure Test’ of Differential pressure transmitter static should be carried

out by connecting the HP and LP sides of the transmitter together and applying
maximum working pressure. At the zero differential pressure adjust zero
adjustment screw to an output of 50% of the transmitter. When applied
maximum working pressure deviation in out reading permitted should be within
the tolerance limits specified by the manufacturer.

f. At Zero differential pressure adjust ZERO adjustment screw so that the standard
pressure gauge reads 0.2 Kg/CM2/3 PSI.

g. With lock valve open and vent valve closed apply an actuating pressure of
approximate full range. Close lock off valve and check system for leaks. When
no fall in pressure is observed i.e. indicates no leaks. Open vent valve and
recheck Zero. Vent low pressure port of DPT to atmosphere.
h. Apply actuating pressures equivalent to 0. 25, 50, 75 & 100% of instrument
range. Record corresponding output readings. Apply 110% signal as a check for
hysteresis.
i. Using vent valve reduce actuating pressures equivalent to 100, 75, 50, 25 and
0% of instrument range Record corresponding output readings.
j. The % error calculated from the results of the above test shall not exceed the
manufacturers stated limits
k. Transmitters with indicating scales shall where necessary have their indicators
calibrated during these tests.

6.6 DIFFERENTIAL PRESSURE SWITCH:

a. Make connections as shown in the figure 6 shown in page no. 14 of 66.

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b. An Electrical continuity meter shall be connected across the switch electrical

terminals to display switch continuity status.

c. For differential pressure switches, pressure shall be applied to the "HP" port only
with the "LP" port open to atmosphere and the equalizing valve closed, provided
switch is calibrated along with manifold fitted.

d. Pressure shall be applied to the process impulse port, using a Dead Weight
Tester, water pump or by the application of regulated pneumatic air supply. The
selection of testing equipment shall depend upon the switch type and process
range.

e. The signal input shall be increased to a value where the switch contacts change
status viz. the threshold position. The value of pressure at threshold position
shall be recorded.

f. The signal input shall be reduced to the pre-test condition.

g. If necessary the set point shall be adjusted to specifications as given in the

engineering data sheet.

h. After calibration switches shall not be subjected to sudden movements,

acceleration or shock and shall be protected from moisture, dirt and large
temperature variations.

i. After testing, all connections and entries shall be sealed to prevent the
subsequent ingress of moisture

STANDARD GAUGE
DIFFERENTIAL
PRESSURE
SWITCH LP PORT

CONTINUITY TESTER

OPEN TO
ATMOSPHERE

COMPARATOR

FIGURE : 6
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6.7 TEMPERATURE INDICATORS:

a. Thermometers shall be inspected for proper ranges and evidence of damage.
b. Make connection as shown in Fig. 7 shown in page no.15.
c. Immerse the bulb in the standard/certified Temperature Calibrator.
d. Thermometers shall be ZERO set of ZERO OFFSET is less that 10% of full
range.
e. Simulate analogue input signals over the full range of the indicator type
instrumentation under test. During calibration, the generated analogue input
signal value shall be usually displayed by using standard test equipment. The
input and impulse signal shall be applied incrementally through 0% - 100% - 0%
as detailed in the calibration sheet.
f. When the input signal is incrementally applied, comparison shall be made
between the signal input as displayed the standard test equipment monitor and
the signal input as displayed by the indicator under test. If necessary, the zero
and span adjustments of the indicator under test shall be altered to minimize or
remove discrepancies between the calibration standard display and the indicator
under test.
g. Thermometers that do not function properly during initial operations shall be
replaced or repaired with prior approval of the Client.
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TEMPERATURE
INDICATOR
STANDARD W/O THERMOWELL
THERMOMETER

WATER OR
SILICON OIL

HEAT SOURCE

TEMPERATURE BATH

FIG. - 7

TEST CIRCUIT FOR CALIBRATION OF

TEMPERATURE INDICATOR

6.8 TEMPERATURE TRANSMITTERS (FILLED SYSTEM TYPE):

a. According to the type of transmitter make connections as shown in figures 8A and
8B shown in page no. 16 and 17 respectively.
b. Immerse bulb in an oil bath fitted with an NPL or equivalent certified transmitter.
c. Connect the output as follows:
(a) For electronic transmitter : to a suitable test meter.
(b) For pneumatic transmitter : to a pneumatic calibrator.
d. Raise both temperature to 50 and 100% of instrument range. Record
corresponding output readings. The % error calculated from the results of the
above tests shall not exceed the manufacturers stated limits.
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6.9 TEMPERATURE TRANSMITTERS (THERMOCOUPLE TYPE):

(CURRENT TO PNEUMATIC AND PNEUMATIC TO CURRENT CONVERTORS FOR
TRANSMISSION OF TEMPERATURE)
a. After checking the instrument connects a suitable pneumatic or electrical supply
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according to a figure 9A and 9B shown in page no. 19.

b. Connect the output as follows:

(a) For Electrical Transmitter - to a suitable test meter.

(b) For pneumatic Transmitter - to a manometer or pneumatic calibrator.
c. Convert the ambient temperature to equivalent millivolt using an approved
conversion table.
d. Transmitter shall be calibrated along with the Thermocouple by using suitable
Equipment that is capable of producing a regulated temperature source.
e. The calibration equipment shall be selected to provide a temperature variation
over the full temperature transmitter process range.
f. The transmitter shall be calibrated using equipment that is capable of producing a
regulated temperature source. The transmitter temperature detection probe shall
be inserted into the calibrating equipment in close proximity to the reference
temperature probe. The transmitter out put is compared to the display as yielded
by the reference temperature probe indication.

g. When the heat source temperature is altered incrementally, time shall be allowed
for the temperature to stabilize before the reference temperature is taken for
calibration purpose.
h. Similar analogue input signals over the full range of the indicator type
instrumentation under test. During calibration, the generated analogue input
signal value shall be usually displayed using standard test equipment. The input
and impulse signal shall be applied incrementally through 0% - 100% - 200% as
detailed on the calibration sheet.
i. When the input signal is incrementally applied comparison shall be made
between the signal input as displayed by the standard test equipment monitor,
and the signal input as displayed by the indicator under test. If necessary, the
zero and span adjustments of the indicator under test shall be altered to minimize
or remove discrepancies between the calibration standard display and the
indicator under test.
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PNEUMATIC

STD: PRESSURE GAUGE

PRECISION VOLTMETER
PRESSURE GAUGE
TEMPERATURE
input TRANSMITTER OUT PUT
DC SOURCE V

REGULATED AIR SUPPLY

POTENTIO METER

FIG.-9A

ELECTRONIC

PRECISION VOLTMETER MILLI AMMETER

TEMPERATURE mA
input TRANSMITTER OUT PUT
DC SOURCE V

POTENTIO METER
FIG.-9B

TEST CIRCUIT FOR CALIBRATION OF

TEMPERATURE TRANSMITTER (THERMOCOUPLE)

6.10 TEMPERATURE SWITCH:

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a. The calibration equipment shall be selected to provide a temperature variation

over the full temperature switch process change.

b. Make the connections to the switch according to figure 10A & 10B shown in page
no. 21.

c. An electrical continuity meter shall be connected across the switch electrical

terminals to display switch continuity status.

d. Switch shall be calibrated by using equipment that is capable of producing a

regulated temperature source. The temperature detection probe of the switch
shall be inserted into the calibrating equipment in close proximity to the
reference temperature probe.
e. This voltage or resistance value whichever has been applied shall be converted
to temperature and recorded with the help of conversion charts.

f. The signal input shall be increased to a value where the switch contacts change
state viz. the threshold position. The value of voltage or resistance at threshold
position shall be recorded.
g. This value of voltage or resistance shall be converted to temperature to obtain
the point where switch changes status.

h. The signal input shall be reduced to pre-test condition.

i. If necessary the set point shall be adjusted to specifications as per engineering

data sheet.

j. After testing all connections and entries shall be sealed to prevent the subsequent
ingress of moisture and dirt. The switch shall not be subjected to large
temperature variations thereafter.

6.11 RESISTANCE TEMPERATURE DETECTOR:

a. The calibration equipment shall be selected to provide a temperature variation

over the full temperature sensor process range.

b. Connections shall be made as shown in Fig.11 shown in page no.22.

c. The RTD shall be calibrated using equipment that is capable of producing a

regulated temperature source. The RTD output is compared to the display as
yielded by the reference temperature probe indication.

d. With the heat source, the temperature is altered incrementally. Time shall be
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allowed for the temperature to stabilize before the reference temperature is taken
for calibration purpose.

e. Simulate analogue input signals over the full range of the RTD sensor under test.
During calibration the generated analogue input signal valve shall be visually
displayed using standard test equipment. The input signal shall be applied
incrementally through 0% - 100% - 0% as detailed on the calibration sheet.

f. When the input signal is incrementally applied comparison shall be made

between the signal input as displayed by the standard test equipment monitor
and the signal input as displayed by the indicator under test.

g. The percentage error between the measured and converted valves shall not be
beyond the manufacturers stated limits.

MULTIMETER

STANDARD OUT PUT WHERE IS

THERMOMETER CHANGE IN RESISTANCE

THERMO COUPLE SENSOR

IN THERMOWELL

WATER OR
SILICON OIL

HEAT SOURCE

TEMPERATURE BATH

FIG. - 11

TEST CIRCUIT FOR CALIBRATION OF

TEMPERATURE DETECTOR (R.T.D.)

6.12 THERMOCOUPLE:

a. The calibration equipment shall be selected to provide a temperature variation

over the full temperature sensor process range.

b. Connection shall be made as shown in Figure 12 shown in page no. 24.

c. When the heat source temperature is altered incrementally, time shall be allowed
for the temperature to stabilize before the reference temperature is taken for
calibration purpose.
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d. The thermocouple shall be calibrated using equipment that is capable of

producing a regulated temperature source. The thermocouple output is
compared to the display as yielded by the reference temperature probe
indication.

f. Simulate analogue input signals over the full range of the thermocouple under
test. During calibration, the generated analogue input signal value shall be
usually displayed using standard test equipment. The input signal shall be
applied incrementally through 0% - 100% - 0% as detailed on the calibration
sheet.

g. When the input signal is incrementally applied comparison shall be made

between the signal input as displayed by the standard test equipment monitor
and the signal input as displayed, by the indicator under test.

h. The percentage error between the measured and converted values shall not be
beyond the manufacturers stated limits.
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MULTI
STD THERMO METER METER

RESISTANCE
MEASSUREMENT

SENSOR W/O THERMOWELL

HEATING SOURCE

TEMPERATURE BATH

FIG. - 12

TEST CIRCUIT FOR CALIBRATION OF

TEMP. DETECTOR (THERMOCOUPLE)

6.13 TEMPERATURE TRANSMITTER (RTD TYPE):

(CURRENT TO PNEUMATIC OR PNEUMATIC TO CURRENT CONVERTORS)

a. Calibrating test equipment shall be provided which can simulate analogue input
signals over the full transmitter range. Usually displayed using standard test
equipment.
b. Connect a precision decade resistance box to the instrument input terminals.

c. After checking the relevant instrument against its specification connects a

suitable air/electrical supply according to figure 13A and 13B shown in page no.
25.
d. Connect the output as follows:

(a) For Electronic transmitter - to a suitable test meter.

(b) For Pneumatic transmitter - to a manometer or pneumatic calibrator.
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e. Transmitter input shall be applied incrementally from 0% - 100% - 0% in steps as

detailed on the calibration sheet.
f. When the input signal is incrementally applied comparison shall be made between
the signal input as displayed by the standard test equipment monitor and
the output as displayed by the Transmitter under test. If necessary the zero and
span adjustments of the transmitter under test shall be altered to minimize or
remove discrepancies between the calibration standard display and
the transmitter under test.
g. The percentage error calculated from the results of above tests shall not exceed
the manufacturer stated limits.

ELECTRONIC

MILLI AMMETER
mA
TEMPERATURE
TRANSMITTER
OUT PUT DC SOURCE

INPUT

DECADE
RESISTANCE BOX

FIG. - 13A
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PNEUMATIC STD: PRESSURE GAUGE

PRESSURE GAUGE

TEMPERATURE
TRANSMITTER

VARIABLE AIR SUPPLY

DECADE RESISTANCE
BOX

FIG. - 13B

TEST CIRCUIT FOR CALIBRATION OF TEMP. TRANSMITTER (RTD)

6.14 LEVEL TRANSMITTER – INTERNAL DISPLACER TYPE – PNEUMATIC /

ELECTRONIC:
a. Fabricate a suitable test rig to enable the float to be operated by raising and
lowering the water level. Connect a water supply to the test rig via a tee piece.
The leg of the tee connected to the water supply shall have a lock off valve and
drain valve fitted. The other leg of the tee piece shall be connected to a glass or
plastic water column secured to the chamber. A common datum line should be
marked on the tube at mid range on the chamber.
b. The transmitter shall be calibrated using water as process fluid if the transmitter
does not have a specific gravity compensation then calibrated output must
compensate for disparity between duty specific gravity and specific gravity of
water (1.0). If transmitter has a specific gravity the adjustment, the adjustment
shall be set at 1.0 for duration of calibration. When the calibration has been
completed, the specific gravity adjustment can be set to the process specific
gravity as specified on the Engineering Data Sheet.
c. If the transmitter is pneumatic, then a regulated 20 psig air supply shall be
connected to the input port, and standard pressure test gauge connected to the
output port shown in figure 16A page no. 28.

d. If the transmitter is electronic, then the remote mounted receiver, either level
indicator or level indicator controller, shall be energized at a normal supply
voltage, and a milliammeter connected in series with the transmitter output. The
meter shall be capable of reading a current variation of 4 - 20 mA DC as shown in
figure 16B page no. 29.

e. With lock off valve open and drain valve closed raise water level to 0, 25, 50, 75
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and 100% of instrument range as indicated on graduated water column. Record

corresponding output readings. Raise the water level to 110% and check against
hysteresis.

f. Use the drain valve to lower the level to 100, 75, 50, 25 and 0%respectively as
indicated on the graduated water column. Record the corresponding output
readings. The percent error calculated from the results of above test shall not
exceed the manufacturers stated limits.

g. Transmitters with indicating scales, shall where necessary, have their indicating
scales also calibrated during this tests.
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PNEUMATIC

PRESSURE GAUGE

FLOAT
TRANSMITTER

AIR SUPPLY

100

DISPLACER
INTERNAL
50

LEVEL GAUGE

FIG. - 16A
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ELECTRONIC

m TEST POINT
A

24 DC
FLOAT JB SUPPLY
TRANSMITTER

100

DISPLACER
INTERNAL
50

LEVEL GAUGE

FIG. - 16B
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6.15 LEVEL TRANSMITTER – EXTERNAL DISPLACER TYPE – PNEUMATIC /

ELECTRONIC:

a. A temporary transparent flexible hose shall be connected to the level

displacer chamber drain valve, and strapped to the displacer leg to display
water level variation as shown in figure 17A & 17B page no. 31 & 32
respectively.
b. The transmitter shall be calibrated in situ. The impulse lines to the vessel
shall be closed the stand pipe vent open and the stand pipe impulse to the
transmitter is open.

c. The transmitter shall be calibrated using water as process liquid. If the

transmitter does not have specific gravity compensation than the calibrated
output must compensate for the disparity between the duty fluid specific
gravity and the specific gravity of water (1.0). If the transmitter has a
specific gravity adjustment, the adjustment shall be set at 1.0 for the
duration of calibration. After the calibration has been completed, the
specific gravity adjustment can be reset to the process specific gravity as
specified on the Engineering Data Sheet.
d. If the transmitter is pneumatic, then a 20 psig air supply shall be connected
to the input port, and a standard pressure test gauge connected to the
output port.
e. If the transmitter is electronic, then the remote mounted receiver, either
level indicator or level indicator controller, shall be energized at normal
supply voltage, and a milliammeter connected in series with transmitter
output. The meter shall be capable of reading a current variation of 4-20
mA DC.
f. For calibration, water level variation shall be obtained by pouring in water
through the open vent, and drawing of through the stand pipe drain valve.
g. With the lock off valves open and the drain valve closed raise water level
to 0% - 50% - 100% - 50% - 0% of instrument range as indicated by the
water column. Record corresponding output readings. Raise water level
to 110% and check against hysteresis. The percentage error calculated
from the results of above test shall not exceed the manufacturers stated
limits.
h. Transmitters with indicating scale, shall where so necessary, have their
indicating scale also calibrated during this test.
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PNEUMATIC : DISPLACER TYPE - EXTERNAL

PRESSURE GAUGE
FLOT TRANSMITTER

TANK SHELL 100%

DISPLACER
50% AIR SUPPLY

0%

LEVEL GAUGE

FIG. - 17A
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6.16 FLOAT OPERATED LEVEL SWITCH:

a. The float switch shall be calibrated in Situ. If the switch is mounted on a stand
pipe, level variation shall be read off on the adjacent level gauge. If the level
gauge has not been installed, then a temporary transparent flexible hose shall be
connected to the level transmitter drain valve, and strapped to the displacer leg to
display water level variation Refer figure 18 in page no. 34.
b. If the switch is installed on a stand pipe, the stand pipe impulse lines shall be
closed and the stand pipe vent open. The stand pipe impulse lines to the level
switch shall be open, and the stand pipe and level switch drain valve closed.
c. If the switch is electrical a continuity meter shall be connected across the
terminals to check and verify the status of the contacts.
d. Water shall now be poured through the vent valve, raising the water lever to a
point where the switch status changes. The water shall then be drained slowly
through the level switch drain valve to observe at what point the switch reverts to
the original status as the level falls.
e. If the switch is direct mounted, the upper impulse line shall be opened and the
lower impulse line closed. a temporary liquid manometer shall be connected to
the level switch drain valve as described in an above.
f. Water shall be poured into the flexible hose. The water shall then be raised to a
point where the switch status changes. The water shall then be drained slowly by
cracking the flexible hose connection on the drain valve. Alternatively, a needle
valve can be tied in to the flexible hose to drain the water. The level at which the
level switch reverts to the original status shall be noted.
All water used for checking the level switch shall be drained and lines flown
through with air on completion of tests.
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LEVEL SWITCH

TANK SHELL 100

FLOATS
50

LEVEL GAUGE

FIGURE 18
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6.17 SOLENOID VALVES:

a. A functional test shall be applied to each valve, on air or gas service by

connecting an air supply to the inlet port and energizing the coil with the correct
electrical power supply.

b. Hydraulic pressure source shall be used where the air pressure required will
exceed that laid down by site safety requirements.

c. The test pressure shall equal the maximum differential pressure for which the
valve is rated by manufacturer. Where this information is not available, the valve
shall be tested with an air pressure equal to 110% of the working pressure at
which the valve will be used.
d. For valves on liquid service, the test procedure shall be same except that water
supply shall be used to simulate liquid service.
e. Application or removal of power depending on operational mode shall close the
valve for 2 way valves, or close the inlet port and divert outlet port to vent port for
3 way valves. Three way valves shall be checked for air leakage at vent which
should be zero when inlet is open to outlet with outlet plugged.

f. Where a manual reset level is provided the reset action shall be checked.

6.18 CONTROL VALVES:

a. Check that, where specified, the lubricator is fitted and charged with the correct
lubricant.
b. If the valve is fitted with a hand wheel, then the hand wheel shall be disengaged
during calibration.
c. With no pneumatic signals applied to the actuator, the valve stem travel plate
resting position with respect to valve stem travel scale shall be checked. This
stem position shall then be checked against engineering data sheet to ensure
conformance to specification.
d. Valve without positioners (Ref figure 20A page no39).

i)If the valve is not fitted with a positioner a regulated air supply adjustable from
0-20 psig shall be connected to actuator signal port.
ii) The signal input shall now be applied incrementally through 0% to 100%
and to 0% of signal input range as detailed on the calibration sheet.
iii) If required, the valve spring zero can be adjusted to obtain the correct
input signal/valve stem travel relationship as detailed on engineering data
sheet.
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e. Valves fitted with positioners (Ref. figure 20B page no. 38).

i) A regulated air supply shall be connected to the positioner supply port.

The supply pressure shall be set at the pressure specified in the valve
actuator data plate.
ii) Calibration equipment as shown in the figure "20B" shall be connected to
the positioner input signal port.
iii) The input signal shall be now applied incrementally through 0% - 100% -
0% of signal input range as detailed on the calibration sheet.
iv) The valve shall take up the same position in the upward and downward
direction with the limits of +5% of the vale stroke reading in the dial
indicator. The hysteresis, if present shall be measured with a micrometer
dial indicator (clock gauge).
v) If required the positioner span and zero settings shall be adjusted to obtain
the correct input signal/valve stem travel relationship as detailed in
engineering data sheet.

f. Fail Safe Action

The input signal shall be applied to drive the Valve stem to 50% travel. The air
supply shall then be turned off and the fail safe action observed and checked
against the engineering data sheet specification, i.e. fail close or open or stay-put
if a lock in relay fitted.
g. Valve stem travel limit switches

If limit switches are fitted, then switch operation shall be checked using continuity
meter when the valve stem calibration is in progress. Switch status related to
stem position shall be included on the instrument calibration sheet (Control
Valves).
h. Valve stem travel transmitter
If the valve is fitted with a valve stem transmitter then calibration shall be as
follows:
i)If transmitter is pneumatic, then a separated regulated air supply set 20 psig
shall be connected to the input port and a standard pressure gauge to the
output. Simulate analogue input signals over the full travel range of
control valve type under test during calibration. The generated analogue
signal valve shall be usually displayed by using standard equipment/ The
input and impulse signal shall be applied incrementally through 0% - 100%
- 0% as detailed on the calibration sheet.

ii) When the input signal is incrementally applied, comparison shall be made
between the signal input as displayed by the standard test equipment
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monitor, and the signal input as displayed by the transmitter under test. If
necessary zero and span adjustments of the transmitter under test shall be
altered to minimize or remove discrepancies between the calibration
standard display and the indicator under test.

i) The control valve shall be stroked after installation.

j) The input signal shall be applied to drive the valve stem to 50% of travel.
The air supply shall then be turned off and fail safe action observed and
checked against the engineering specification i.e. fail close or fail open or
stay put if a lock in relay is fitted.

k) If limit switches are fitted, then switch operation shall be checked using a
continuity meter when the valve stem calibration is in progress. Switch
status related to stem position shall be included on the instrument
calibration sheet
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Pressure Gauge

Pneumatic
Actuator
Variable air supply

Control valve
without
positioner

FIG. - 20A

Pressure Gauge

Positioner
Std :Pressure Gauge
Regulated Air Supply

Pneumatic
Actuator
Variable Air Supply

Control
Valve

FIG. - 20B

TEST CIRCUIT FOR CALIBRATION OF

CONTROL VALVE
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6.19 BALL VALVES:

a. PRE-TEST CHECKS

Before the ball valve is operated through full travel the following conditions shall
apply.
i) Accumulator (if fitted) is charged with nitrogen to a pressure (as stated on
vendors data sheets) via the inlet valve, and the inlet valve is then closed
with the Nitrogen feed line disconnected.
NB : It is essential that accumulator is charged with nitrogen before
hydraulic system pressurized.
ii) The hydraulic oil system isolation valves are open. This includes the
isolation valve to the accumulator (if fitted).
iii) Hydraulic system drain valves are closed including drain valve on
accumulator (if fitted).
iv) The actuator speed control throttle valves are fully open.
v) The hydraulic actuator system is pressurized as per Vendors data sheet.
vi) Air has been vented from the actuator system via the bleed valves.
vii) Any hydraulic oil leaks are eradicated before testing begins.
viii) Electrical power supply is connected to locally mounted mode control
switch.
ix) Electrical power supply is connected to the `remote control' terminals to
energies or de-energies the `open and close solenoids'.
x) Electrical power supply is connected to the shutdown over-ride solenoid. If
two separate shutdown over-ride solenoids are fitted, then the two solenoids
shall be powered from two separate electrical power supplies.

b. BALL VALVE COMPONENT TESTS

Where fitted, the following components shall be checked to ensure correct

operation.

I) Transducer (4-20 mA input/output - 100% ball valve travel).

II) Travel indicator (mechanical).
III) Position transmitter (4-20 mA output).
IV) Position transmitter (3.0 - 15.0 PSIG output).
V) Limit switches.

vi) Pressure gauges. The gauges can be observed during pressurization

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and depressurization to assess correct operation. Defective components

shall be replaced.
vii) Mode switch operation (Auto - close - open)

c. BALL VALVE ACTUATION

The following operations shall be checked out where applicable, and

implemented as detailed.

i) Local manual actuation, using the mode switch selector in the open and
closed positions.
ii) Local manual control via accumulator with main hydraulic system isolated
and feed line de-pressurized. Under these conditions the system shall be
actuated to check that the valve can be operated through three full
strokes.
iii) Remote operation of the valve with the mode switch in the auto position.
(open-Close action).
iv) Remote operation of the valve via a 4-20 mA analogue command signal.
(Open-Close action).
v) Remote fail safe action with the mode switch in the `auto' position and the
open and closed solenoids de-energized.
vi) Operation of the override shut-down solenoid(s). The valve shall be
moved under local or remote command action to the opposite position on
the travel from that position designated as the fail-safe position. The
shutdown solenoid(s) shall then be de-energized to check that the valve
moves to the fail-safe position.

d. BALL VALVE FUNCTION CHECKS

i) When the pre-test checks listed above have been completed where
applicable, the ball valve shall be traversed through full travel in both
directions.
ii) Motion of the ball valve spindle can actuate the components listed below.
If fitted, these items should be function checked during dynamic operation
of the ball valve.
Item A : Limit Switches

Actuation of the limit switches to be checked as the ball valve reaches the
extremity of spindle travel, where the switch changes state.

Item B : Mechanical Travel Indicator.

The indicator shall be observed through full travel to confirm that the ball valve
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spindle is moving through full traverse to the mechanical stop and that the
actuator is driving the spindle in the correct direction as depicted by the travel
indicator.
Item C : Position Transmitter.
The analogue output calibration shall be checked against linear increments of
mechanical travel indicator. Intermediate points shall be checked and a
transmitter calibration sheet record kept.
Item D : Current to Hydraulic Power Transducer.
A 4-20mA command signal shall actuate the ball valve through full travel as
depicted by the mechanical travel indicator. Intermediate points shall e checked
and transmitter calibration sheet record kept.
Item E : Command Signal Transducer.

The 4-20mA command signal input calibration shall be checked against

corresponding valve travel and a transmitter calibration sheet record kept.
e. MODE SWITCH LOCAL CONTROL
Local control shall be checked as follows:
i) Move mode selector switch to close position. Valve should close.
ii) Move mode selector switch to open position. Valve should open.
iii)
Move the valve to the opposite position of the fail safe position. Switch
off the electrical supply to the mode switch. Valves should move to the
fail safe position. Switch back electrical supply on.
iv) Move the valve to the opposite position of the fail safe position. Close
the actuator hydraulic inlet isolation valve, and de-pressurize the inlet
line. The valve should move to the fail-safe position.
6.20 CYLINDER VALVE:

a. Connect the test instruments to provide an input signal 0 to 100% of

range according to figure 21 shown in page no. 42.
b. Calibrate the device using Manufacturer's published data and method.
c. Check the limit switches for proper action if required.
d. Cylinder operated valve shall be calibrated for 0% and 100% of range only.
e. After calibration, valves shall be protected from damage, moisture and dirt.
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Pressure
Gauge

Continuity Tester

FIG - 21

TEST CIRCUIT FOR CALIBRATION OF

CYLINDRICAL VALVE

6.21 SAFETY RELIEF VALVE:

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a. Inspection, Testing and Handling Equipment

The test fluid, air or gas should be filtered to ensure that no particles of foreign
matter pass through into the valve. The test equipment itself should be
constructed of such material that there is no possibility of rust or scale forming,
which could be blown through into the valve with resultant damage to the seat
surfaces or preventing a tight shutoff. Before testing the test equipment shall be
blown out with high pressure air to remove any dust or particles which may have
accumulated inside. The inlet side of the valve itself shall be very carefully
cleaned to ensure that there is no dirt, dust or loose particles adhering to the
inside of the nozzle or the underside of the disc. Only new gaskets and/or rings
of appropriate size and rating shall be used when pressure testing relief valves.

Accurate Gauge
Standard Gauge
: Class 0.5
PSV

Inst Air
N2
Accurate Gauge
Max Press Air
: 120 barg Chamber

Manifold Max Press

V/v Vent : 8 barg

Water
Tank
Air Driven
Fluid P/p
Max Press
: 1130 barg * Test chamber to be hydro tested at
1.5 times the operating pressure.

 All relief valves shall be mechanically protected on both inlet and outlet
flanges faces and clearly identifies and tagged with project system
numbering.
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 Before testing, they shall be store in the upright position on pallets or

shelved in clean dry warehouse.

 Before popping test, clarify whether liquid service or Air/Gas service for
safety valve.

 Carry out the valve lift test. The valve shall be lifted three (3) times at the
design set pressure.

b. Setting and Testing of Relief Valves.

i. Cold Setting of Valves.

A. Valves will normally be set in cold condition on the test bench. The valve
will be set by gradual application of hydraulic pressure and adjusting the
setting mechanism so that the valve starts to lift at its registered `cold set
pressure'.
B. The valve will normally be first set by an applied hydraulic pressure. It
will subsequently be lifted three times by the further application of
hydraulic pressure in the case of valves on liquid duty and by air/nitrogen
pressure in the case of valves on vapor duty.
C. Valve operation above 70 barg to be tested for lift using hydraulic
mediums only. Each test should meet the following criteria for reset
pressure.

Cold set pressure. Valve Cold set pressure. Valve

seat 1.25” dia or less or “H” seat exceeding 1.25” dia or
orifice and smaller “J” orifice and smaller
over 6.9 barg 10% 10%

4.4 - 4.8 barg 8% 5%

0.69 - 4.1 barg 5% 3%

< 0.69 barg 0.14 barg 0.07 barg

ii) Leak Testing of valves

After setting of lifting or reset pressures, the valve seat shall be tested for
tightness by applying nitrogen gas to the inlet side of the valves. The applied
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pressure of nitrogen shall be 90% of cold set pressure. The leakage rate is
measured by a bubble bath fixed to the outlet side of the valve, shall not exceed
the rate listed below. The bubble count shall not start until the pressure has
been applied for 2 minutes and the duration of count shall be over a 2 minute
period for valves up to 4 inches inlet; for valves above 4 inches inlet count shall
be over a 5 minutes period. If a valve has a cold set pressure greater than
68.96 barg it is preferable to leak test with gas over water.

The maximum leakage rate shall be;( refer API527 3th EDIT – bubble test ).

Below 6.9 Mpa

Bubble/Minute
G orifice and large
20
F orifice and
smaller 40

Above 6.9 Mpa

Bubble/Minute
G orifice and large
30
F orifice and
smaller 60

C. Valve subject to back pressure - Body test.

Valves subject to back pressure during the normal course of operation will have a
hydraulic test equivalent to 1.5 times the maximum back pressure that the valve will
normally operate under, applied to the outlet side of the valve.

D. Valves with balancing or sealing bellows:

Any bellows showing signs of deformation will be rejected. After all other tests have
been carried out the bellows will be tested by applying 10 psig air/nitrogen (unless
otherwise specified) in the outlet branches of the valve with a soap solution over the
bonnet air vent. Prior to the test the vent will have been proved clear by rodding with
wire. No leakage will be permitted

6.22 RELAY, BOOSTER & CONVERTER:

1. Make connections as shown figure 22A and 22B on page no. 47 to provide input
and output indication of 0 and 100% of range
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2. Calibration shall fix accuracy values of 0%, 50% and 100% of range.

3. Set direct or reverse control action as specified for specification loops.

PRESSURE GAUGE STD: PRESSURE

GUAGE

RELAY
OR
BOOSTER
CALIBRATING AIR SUPPLY

REGULATED AIR SUPLY

FIG. - 22A

MILLI-AMMETER

STD: PRESSURE
GUAGE
mA
E/P
CONVERTER

VARIABLE CURRENT
SOURCE

REGULATED AIR SUPLY

FIG. - 22B

TEST CIRCUIT FOR CALIBRATION OF

RELAY OR BOOSTER & CONVERTER

6.23 PNEUMATIC CONTROL CIRCUIT PRESSURE TEST:

a. Blow down air line clean.

b. Disconnect air consuming pilots, if any from the section of tubing to be tested.
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c. Connect the test assembly as shown in figure23 in page no. 47.

d. Operate the test assembly for a 3-15 psig system.

e. Open the valve and adjust the pressure regulator until the red pointer reads 15
psi.

f. Adjust precision relay, till black pointer reads 15 psi.

g. Close Valve. A drop in pressure as indicated by the black pointer will indicate a
tubing leak.

h. Permissible leak tolerance.

Pressure shall not fall by more than 1 psig in 10 minutes

PRESSURE REGULATOR

VALVE
TO TEST LINE
AIR SUPPLY
INPUT
AIR SUPPLY

CONTROLLER
OF RELAY

RED BLACK
POINTER POINTER

DUPLEX
PRESSURE GAUGE

Fig. 23

6.24 ELECTRONIC RECORDERS:

a. Ascertain that the pen properly inks and writes on the chart.
b. Install ink supply if required.
c. Make connections as shown in Figure 24A, 24B and 24C on page 48 to provide
an input signal 0 to 100% of range.
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d. Install the chart if required and check scale range to match specification.
e. Calibration check shall fix accuracy values at 0%, 50% and 100% of range.
f. Calibrate the device using Manufacturer's published data and method.

6.25 PNEUMATIC RECORDER:

a. Ascertain that the pen properly inks and writes on the chart.

b. Install ink supply if required. [Must to provide record on the chart].

c. Make connections as shown in Figure 25 to provide an input signal 0 to 100% of

range shown in page no. 49.
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d. Install the chart if required and check scale range to match specification.

e. Calibration check shall fix accuracy values of 0%, 50% and 80% of range.

f. Calibrate and device using manufacturers published data method.

PRESSURE GAUGE

RECORDER

REGULATED AIR
CALIBRATING AIR SUPPLY SUPPLY

COMPARATOR

FIG. 25

TEST CIRCUIT FOR CALIBRATION OF

PNEUMATIC RECORDER

6.26 PRESSURE & TEMPERATURE RECORDERS:

a. GENERAL

Calibration of zero span and linearity is controlled by the adjustment of the

interconnecting linkage. In a typical instrument, the mechanical motion of a
measuring device transmitted through the linkage, to a pen or pointer.
Instruments having multiple pens, will contain separate linkages for each
system. Although the mechanical configuration of the linkage, may differ in
appearance for Instruments from different manufacturers, the basic linkage
function of transferring the mechanical motion from each device to another,
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remains the same.

b. CALIBRATION CHECK – PRESSURE RECORDERS

i. Connect the recorder to the Calibration setup as shown in Figure 26A or

26B in page 52 as applicable.
ii. With zero pressure applied to the recorder "pressure input", adjust the pen
to record zero on the chart.
Adjust zero by adjusting the set screw, (Figure 26D), as necessary.
iii. Apply 100% pressure (full range) and verify that the pen moves across the
scale to the 100% pressure indication.
Adjust span with the Range screw (Figure 26D), as necessary.
iv. Apply 50% of the pressure range and verify that pen indicates 50%
pressure on the chart.
If it does read 50% reading, repeat step (2) and (3) here above.
v. Typical points of Calibration for initial check on the recorder to ascertain its
usability are made at 0%, 50% and 100% of the operating span. For
example a recorder with range of 0-500 psig would have input check at 0,
250 and 500 psig. Three point calibration check is a minimum
requirement.
vi. Subsequently, the Recorder shall be subjected to Calibration checks at
25% and 75% of the Full Range, prior to releasing the instrument for use
in the field.
vii. Some times the instrument may be out of calibration to reach an
acceptable level after five point Calibration check at 0%, 25%, 50%, 75%,
100% . In this case even the above checks are repeated until the
instrument comes within the specified tolerance of the true Calibration
span (i.e. Five point Calibration).
viii. The output versus input readings which will be noted during calibration
should be written down and finally filled up in the Calibration sheet
provided for the record purpose.
c. CALIBRATION CHECK – TEMPERATURE RECORDERS

i. Connect the temperature recorder to the Calibration set-up as shown in

Figure.26C in page 53.

ii. Adjust the pen to read ambient Temperature on the chart by adjusting the
zero adjust screw.

iii. Full temperature range between maximum of the unit and the ambient is
required to be checked and adjusted until the instrument comes within
specified tolerance of the true calibration span (e.g. 4 point calibration).

iv. The output versus input readings which will be noted during Calibration
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should be written down and finally filled up in the Calibration sheet

provided for the record purpose.

INSTRUMENT TO BE CALIBRATED
TEST GAUGE

BLOCK VALVE REGULATOR

BLOCK VALVE
VENT
VALVE
SUPPLY

LOW PRESSURE RECORDER

FIG. - 26A

LOW PRESSURE RECORDER

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Instrument to be calibrated

Block valve

DEAD WEIGHT TESTER

FIG. - 26B

HIGH PRESSURE RECORDER

STA NDA RD
THERMOMETER

TEMPERATURE
RECORDER

WATER OR
SILICON OIL

TEMPERATURE
BULB

HEA T SOURCE

TEMPERATURE BATH

FIG. - 26C
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RANGE ARM LOCK SCREW

STATIC PRESSURE
ELEMENT

PEN MOUNT
PEN SHAFT
LINK RANGE ARM
90 CLAMPLOCK
SCREW
PEN ZERO ADJUST
SCREW
LINK SCREWS TUBING
DRIVE LINK CONNECTION
THUMB NUT THUMP NUT
LOCK SCREW
LEVER ARM

RECORDER CHART

FIG. - 26D

STATIC PRESSURE PEN LINKAGE

6.27 CHECK OF ORIFICE PLATE

a) Confirm orifice plate is not damaged or shows signs of corrosion.

b) Check upstream orifice marking contain the following.

 The word “upstream”

 The tag number
 The ANSI flange class, followed y “RF”
 The nominal size in DN (in mm)
 The measured orifice diameter (in mm)

c) Check difference between any two measurements of the plate thickness is within
0.00DN (in mm)

d) Check that the surface finish of the throat and plate are free from visible
scratches and indentations.

e) Check throat edges are sharp and free from burrs. Check there is no light reflected
from the corners of the square edge plates.

f) Confirm that location and size of the bleed hole / vent hole (where applicable)
confirms to requirements for orifice type.

g) Measure and confirm diameter of orifice(d) at upstream flange face on the

horizontal, 80’ and 120’ axis.
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h) Record the calibration test result on check sheet form.

6.28 FLOW METER(ULTRASONIC, TURBINE METER, THERMAL TYPE)

a) In case of ultrasonic, turbine meter and thermal type, basically it does not need any
calibration test at site but function test at site but function test and visual check
only. These meters will be checked for range using the HART communicator
against.
b) Manufacturer’s pre dispatch calibration report shall be made available.
c) Record the calibration test result on check sheet form.

6.29 FIRE & GAS SYSTEM

a) The fire & gas detection system generally compromises of strategically placed field
sensors and a centrally located alarm / display panel and control system.
b) The F&G control system is also linked to the F&G protection system which
compromises of fire water pumps, the sprinkler system, fire hydrants and the foam
monitor.
c) The sensors for the F&G detection system can be tested using any one of the
following.
 Gas ampoules or cylinders containing calibration gas samples.
 Smoke canisters
 UV / infrared radiation emitters
 Heat source
 Source of flame
Where voting logic is involved, then each combination of the activities inputs shall be
tested and all resultant outputs checked and verified.
d) The fusible loop shall be checked by dropping the line pressure and verifying the
actuation of the control valve.

e) Similarly, the sprinkler system can be checked and verified by simulating the alarm
condition and ensuring that the solenoid of the line control valve gets operating
signal.
f) The alarm should be energized and the “TEST” , “ “ACCEPT” and “RESET” buttons
operated to ensure that the display windows are functional and that the alarm
sequence is operational.
NOTE:- Prior to testing the F&G system ensure that all personnel working on
the same, to avoid panic due to frequent sounding off of the alarm.
g) The complete F & G system including the ESD checked and verified against the
F&G cause and effect diagram.